KR101175281B1 - Inductor core, inductor using the same and method thereof - Google Patents
Inductor core, inductor using the same and method thereof Download PDFInfo
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- KR101175281B1 KR101175281B1 KR1020100113470A KR20100113470A KR101175281B1 KR 101175281 B1 KR101175281 B1 KR 101175281B1 KR 1020100113470 A KR1020100113470 A KR 1020100113470A KR 20100113470 A KR20100113470 A KR 20100113470A KR 101175281 B1 KR101175281 B1 KR 101175281B1
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Abstract
The present invention relates to an inductor core, an inductor using the same, and a method for manufacturing the same. By stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therein, through the perforations, and integrating and fastening, there is no separate impregnation process. An inductor core, an inductor using the same, and a method of manufacturing the same are provided for forming an amorphous inductor core and using the same.
To this end, the inductor core of the present invention comprises: an amorphous laminate comprising a plurality of single thin plates of amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.
Description
The present invention relates to an inductor core, an inductor using the same, and a method for manufacturing the same. More specifically, by stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therein, through the perforations, and aligning and fastening them integrally, The present invention relates to an inductor core, an inductor using the same, and a method of manufacturing the same, for forming an amorphous inductor core without using an impregnation process and forming an inductor using the same.
Induction devices are used in a variety of electronic components such as transformers, choke coils, inductors, noise countermeasures, and the like. Most induction devices consist of a core comprising a soft ferromagnetic material and one or more coils surrounding the core. These inducers are optimized for their type to operate at the desired frequency from DC to kHz.
In particular, the soft magnetic material is selected depending on the combination of the required properties, the usefulness of the material in any form that enables effective manufacture, and the size / cost required for use in a given market.
In general, preferred soft magnetic materials exhibit high saturation induction, high permeability and low core loss to minimize core size and low saturation coercivity. (silicon steel sheets), ferrites, amorphous metals and the like are known.
Specifically, the silicon steel sheet is inexpensive and has a high density, but has a limit of high magnetic core loss in high frequency applications. In addition, ferrite has a low saturation magnetic flux density and poor temperature characteristics, and therefore, ferrite is easily saturated magnetically and is not suitable for high power applications such as coil components of large capacity inverters and power supplies and transformers for power distribution. In addition, the amorphous metal has a disordered structure similar to the liquid state, and exhibits various characteristics different from the existing crystalline materials by quenching the molten liquid metal, and particularly, exhibits excellent soft magnetic properties.
These amorphous metals are classified into iron (Fe) and cobalt (Co) based on their main components.In the case of iron, the saturation magnetic flux density is high and the core loss is smaller than that of silicon steel. In the case of the cobalt system, the magnetic permeability is high and the core loss and coercive force are small.
In particular, the amorphous metal has no crystal structure and thus does not exhibit crystalline magnetic anisotropy, in which magnetism is different depending on the crystal direction. Accordingly, since amorphous metals have a relatively large influence of induced magnetic anisotropy, different magnetic properties can be obtained by applying a magnetic field during heat treatment. For example, when an amorphous metal applies a magnetic field in the circumferential direction of a toroidal magnetic core at a high temperature below Curie-temperature (Tc), the ratio of saturation magnetic flux density (Bs) and residual magnetic flux density (Br) High squarness (Br / Bs) defined can obtain high characteristics. On the other hand, in the amorphous metal, when the magnetic field is applied in the height direction of the magnetic core, a low angular ratio can be obtained.
For reference, products using the high-angle ratio feature include a magnetic amplifier for a switched-mode power supply (SMPS), a spark killer bead core, a magnetic modulator, and a magnetic switch.
Moreover, amorphous metals are in the spotlight as soft magnetic materials for magnetic cores in place of silicon steel sheets or ferrites because of their characteristics of lower core loss and eddy current loss than other soft magnetic materials. Such amorphous metals have excellent response to high frequency characteristics due to eddy current losses such as high efficiency, large electrical resistivity, noise suppression characteristics due to high permeability and high saturation flux density, DC bias characteristics, and miniaturization requirements.
For reference, products using low core loss characteristics include choke cores, high frequency transformers for inverters, transformers for transformers, and various reactors. Products using high permeability characteristics include pulse transformers, boost transformers, audio transformers, current transformers, and noise. Filter and the like. In this case, the magnetic core is divided into a relatively small gap type toroidal core and a large rectangular cut core.
Hereinafter, a manufacturing method for a conventional amorphous magnetic core will be briefly described.
First, as described above, the amorphous metal is sprayed onto a cooling roller made of a high thermal conductor (copper, etc.) rotating at a high speed in a molten liquid state and cooled at a high speed of 10 6 ° C / sec or more, thereby providing a uniform thickness. It is provided as a thin, continuous ribbon with:
Thereafter, the slitting process is performed. That is, the amorphous metal ribbon wound on one side is wound after being wound in a toroidal or rectangular shape while being wound on a support bar (or support rod) on the other side while the tension is adjusted.
Next, a heat treatment process is performed. In other words, the wound toroidal or rectangular amorphous metal is heat-treated to relieve magnetic properties and stress during winding.
Thereafter, an impregnation and drying process is performed. That is, the heat-treated toroidal or rectangular amorphous metal is dipped in the shape maintaining impregnation liquid and then dried.
Then, the cutting process is performed. That is, a gap is formed to impart unique magnetic properties to the gap type amorphous toroidal core or amorphous cut core to provide an amorphous magnetic core. At this time, the amorphous magnetic core is assembled to the case to complete the final product.
Amorphous metals, however, exhibit superior magnetic properties compared to other ferromagnetic materials, but there are difficulties in material processing due to their physical properties. That is, in the related art, excessive wear may be generated in a manufacturing tool or the like in performing a cutting process for forming a gap for imparting unique magnetic properties to an amorphous toroidal core or an amorphous cut core.
Meanwhile, Korean Patent Laid-Open Publication No. 2005-67222 discloses cutting an amorphous metal strip material to form each of a plurality of planar thin plates, and then laminating and aligning the thin plates to form a thin laminate having a three-dimensional shape, and the magnetic of the part. After annealing the thin plates to improve the properties, a method of adhering the thin laminate as an adhesive has been proposed. That is, Korean Patent Laid-Open Publication No. 2005-67222 discloses a structure for assembling in parallel to form a parallel laminate adjacent to each other by adhering a thin laminate with an adhesive without a bracket (bracket). When the single thin laminates of type I are combined to form an 'EI' or 'square' amorphous magnetic core, it is difficult to mechanically assemble by adjusting the spacing and parallelism for each single thin laminate. Occasional cases may require recalibration to reveal the core shape.
In addition, Japanese Patent Laid-Open No. 1985-21511 proposes a structure in which a laminate is assembled and fixed in a non-penetrating manner by using two pairs of iron core fastening members and bolts / nuts. A structure for assembling a laminate using bolts / nuts has been proposed. These Japanese Patent Laid-Open Publication Nos. 1985-21511 and 1999-186082 have an external structure for fastening the laminate in a non-penetrating manner to increase the volume of the assembly, and to laminate the laminate through bolts / nuts by the external structure. Because of the assembly, there is a limit that is difficult to align the laminate.
In particular, in the case of such an amorphous magnetic core, when a single thin plate is fixed to form a constant thin laminate, an adhesive is deposited and bonded. A large-capacity induction apparatus [for example, having a weight of 7 kg to 10 kg and having a 20 cm × Having a size of 10 cm × 2 to 5 cm]. That is, a large-capacity induction device used to improve efficiency such as wind power or solar power generation needs to perform a heat treatment process following vacuum impregnation when forming a thin laminate using an adhesive, and equipment for performing such a process is essential. As it is required, the facility cost for accommodating a large-capacity induction apparatus is expensive, and the impregnation and heat treatment process takes a lot of time.
Therefore, in the present invention, by stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therein through the perforations to be integrally aligned and fastened, forming an inductor core without a separate impregnation process and forming an inductor using the same. An object of the present invention is to provide an inductor core, an inductor using the same, and a method of manufacturing the same.
The objects of the present invention are not limited to the above-mentioned objects, and other objects and advantages of the present invention which are not mentioned can be understood by the following description, and will be more clearly understood by the embodiments of the present invention. It will also be readily apparent that the objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
In order to achieve the above object, the inductor core of the present invention comprises: an amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.
The fastening part may include: a support having one end fixed to the upper cover or the lower cover and extending through a perforation of the amorphous laminate; And a fastening member coupled to the other end of the support to integrate the upper cover, the amorphous stack, and the lower cover.
The fastening part is characterized in that the support rod for welding or riveting the upper cover and the lower cover through the aperture of the amorphous laminate.
The amorphous laminate is formed of any one of I type, C type, E type, T type, and trapezoid.
The inductor core of the present invention further includes an anti-oxidation coating film formed on the outer circumferential surface of the core by spraying or dipping.
The upper cover and the lower cover, characterized in that formed in any one of the type I, C, E, T, trapezoid.
On the other hand, the inductor of the present invention, at least two inductor cores are integrally fastened by stacking a plurality of single thin plate of amorphous metal having a perforation formed, and combined to form a magnetic circuit; A bobbin mounted to and insulated a leg of the inductor core; And at least one coil wound around the bobbin.
Each of the inductor cores may include: an amorphous laminate including a plurality of single thin plates of an amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.
The inductor core further includes at least one spacer inserted into a coupling surface of the amorphous laminate.
The inductor core further includes a fixing band in the form of a strip for integrating a plurality of amorphous laminates.
The inductor core may be implemented in any one of a multi-gap type structure, a normal gap type structure, a one-way type structure, and an L type structure.
In addition, the inductor of the present invention comprises: an inductor core for stacking a plurality of single thin plates of amorphous metal having perforations formed therein and forming a magnetic circuit in at least two combinations; A case including the inductor core therein and having a flange for distinguishing a portion corresponding to a leg of the inductor core at an outer circumference thereof; And a coil wound along the flange of the case.
The inductor core may include an amorphous laminate including a plurality of single thin plates of an amorphous metal having at least one aperture formed therein; Upper and lower covers for covering upper and lower portions of the amorphous laminate; And a fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.
The inductor core may be implemented in a normal gap type structure.
On the other hand, the manufacturing method of the inductor of the present invention, the first step of producing a single thin plate formed with a perforation from the ribbon of amorphous metal; A second step of forming an inductor core by integrating the amorphous laminate, the upper and lower covers by disposing an upper and lower cover on the amorphous laminate on which the single thin plate is laminated, and then engaging fastening portions for perforations; Performing a heat treatment on the inductor core; And a fourth step of manufacturing the inductor on which the magnetic circuit is formed by combining the heat-treated inductor core into at least two.
The third step may be performed before or after the anti-oxidation coating process on the outer wall of the inductor core.
The third step is characterized in that carried out for 2 to 10 hours at a temperature condition of 380 ℃ ~ 450 ℃.
In the fourth step, a bobbin is coupled to a leg of the inductor core, and a coil is wound.
In the second step, the inductor core may be combined to form a magnetic circuit having any one of a multi-gap type structure, a normal gap type structure, a one-way gap type structure, and an L type structure.
In the fourth step, the coil is wound after the inductor core is enclosed in a case having a flange.
As described above, the present invention has the effect of rapidly forming an amorphous inductor core without a separate impregnation process by stacking a plurality of single thin plates of amorphous metal having at least one perforation formed therethrough through the perforations to be aligned and fastened. have.
In addition, since the present invention does not perform a separate impregnation process, it is easy to form a large inductor at low cost of equipment investment.
In addition, the present invention has the effect of reducing the core loss (core loss) compared to the inductor core manufactured by cutting after winding the core.
1A is an exploded perspective view of a first embodiment of an inductor core according to the present invention;
1B is a perspective view of the inductor core of FIG. 1A,
2A is an exploded perspective view of a second embodiment of an inductor core according to the present invention;
FIG. 2B is a perspective view of the inductor core of FIG. 2A;
3A is an exploded perspective view of a third embodiment of an inductor core according to the present invention;
3B is a perspective view of the inductor core of FIG. 3A,
4 is a configuration diagram of a first embodiment of an inductor configuration according to the present invention;
5 is a configuration diagram of a second embodiment of an inductor configuration according to the present invention;
6 is a configuration diagram of a third embodiment of an inductor configuration according to the present invention;
7 is a configuration diagram of a fourth embodiment of an inductor configuration according to the present invention;
8A and 8B are schematic views of a fifth embodiment of an inductor configuration according to the present invention;
9 is a flowchart illustrating a method of manufacturing an inductor according to the present invention;
FIG. 10 is a graph illustrating a comparison of the inductor core of FIG. 3A and FIG. 3B with a conventional inductor core. FIG.
BRIEF DESCRIPTION OF THE DRAWINGS The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings, It can be easily carried out.
In the following description, well-known functions or constructions are not described in detail since they would obscure the invention in unnecessary detail. Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.
Prior to describing the present invention, the term 'amorphous laminate' refers to a three-dimensional matrix for forming a core by laminating and aligning a plurality of single thin plates having a predetermined shape. At this time, the amorphous laminate does not perform a separate impregnation process for bonding or assembling each single thin plate, and the upper and lower covers, the amorphous laminate and the upper and lower portions for fixing and assembling a plurality of stacked single thin plates. The coupling state and the support for fastening to the cover, etc. (hereinafter referred to as "assembly bracket for assembly") is maintained in the engaged state. However, the amorphous laminate may be subjected to an anti-oxidation coating process around the outer wall in a short time by spraying or dipping rather than an impregnation process in which a plurality of single thin plates are stacked in an impregnation solution for a long time. This is not only for the purpose of preventing oxidation, but also for preventing the debris of the debris of the amorphous metal material due to punching molding. At this time, the antioxidant coating agent may be a coating agent made of a material such as epoxy (epoxy), silicon (silicone), urethane (urethane).
In addition, a single sheet is a planar sheet of amorphous metal material, which is formed through a cutting process by a variety of conventional methods. In this case, the single thin plate is cut into a shape similar to a letter identified as "I" or "C", and the amorphous laminate in which the I-type single thin plates are stacked and aligned is referred to as "I-type laminate", and C-type single An amorphous laminate in which thin plates are stacked and aligned is referred to as a "C laminate" below. Here, in the case of the I-type single thin plate, the cutting is performed after slitting is performed, and in the case of the C-type single thin plate, the slitting is formed and then punched out.
In particular, the I-type and C-type laminates are provided with joining holes (i.e., through-holes) with the mounting bracket on each single sheet surface for fixing and joining by the mounting bracket. To this end, the I-type single sheet is punched while cutting, and the C-type single sheet is punched while punching. In addition, type I single thin plates and type C single thin plates can also be produced by an etching process.
Meanwhile, in the present invention, an inductor core may be implemented by using an I-type laminate and a C-type laminate, and an inductor core manufactured using one I-type laminate (see FIGS. 1A and 1B to be described below) I-type inductor core "), an inductor core manufactured by combining three I-type laminates to form a C-type laminate (see FIGS. 2A and 2B to be described below) (hereinafter referred to as" C-type inductor core "), An inductor core (see FIGS. 3A and 3B to be described later) manufactured using a C-type laminate (hereinafter, referred to as "C-type single inductor core") will be described in detail.
As described above, since the inductor core for manufacturing the inductor does not perform a separate impregnation process and heat treatment process, a large inductor can be manufactured quickly and easily, and as a result, a low cost can be manufactured.
1A is an exploded perspective view of a first embodiment of an inductor core according to the present invention, and FIG. 1B is a perspective view of the inductor core of FIG. 1A.
The
As described above, the I-
Here, the I-
Meanwhile, the
In addition, the
In addition, the method of assembling using the bolt-nut structure by the
Here, the
At the time of fastening to the above-described upper cover 12-I stacked body 11-
As such, the I-
On the other hand, the I-type single thin plate may be cut differently in length as needed. This is to distinguish and form the inductor cores for the left and right legs of the coil in which the upper and lower yokes and bobbins are wound when the rectangular inductor is formed (see FIGS. 2A and 2B to be described later). ).
Figure 2a is an exploded perspective view of a second embodiment of the inductor core according to the present invention, Figure 2b is a perspective view of the inductor core of Figure 2a.
The
The
Each of the first to third I-
Figure 3a is an exploded perspective view of a third embodiment of the inductor core according to the present invention, Figure 3b is a perspective view of the inductor core of Figure 3a.
The
The C-shaped
Hereinafter, an inductor configuration using the inductor core described above will be described. For convenience of description, the bobbin and the coil are not shown in the inductor.
On the other hand, the inductor arranges a spacer in the gap between the inductor cores (that is, the magnetic gap), where the gap between the inductor cores is reduced to reduce the eddy current loss in consideration of the characteristic that the inductance is lowered as the magnetic gap becomes farther apart. Configure by adjusting.
In addition, when assembling at least two inductor cores, the inductor is preferably fastened and fastened with a strip-type separation prevention fixing band made of sus material. At this time, the inductor is finally insulated by performing varnish molding with any one of epoxy, acrylic, and urethane.
4 is a configuration diagram of a first embodiment of the inductor configuration according to the present invention.
The
5 is a configuration diagram of a second embodiment of the inductor configuration according to the present invention.
The
6 is a configuration diagram of a third embodiment of the inductor configuration according to the present invention.
The
7 is a configuration diagram of a fourth embodiment of the inductor configuration according to the present invention.
The
8A and 8B are schematic diagrams of a fifth embodiment of the inductor configuration according to the present invention.
The
The pair of C-type
9 is a flowchart illustrating a method of manufacturing an inductor according to the present invention.
First, after the slitting process is performed, a single thin plate is generated (S901). In other words, type I single sheet is produced by cutting an amorphous metal ribbon provided as a thin, continuous wide ribbon having a uniform thickness after slitting to a desired width, and forming a type C single sheet using a wide amorphous metal ribbon to a desired width. After slitting, it is punched into Form C or produced by etching. At this time, perforations are simultaneously formed in a single thin plate.
Next, an inductor core is formed using an amorphous laminate in which a plurality of single thin plates are stacked (S902). In other words, the inductor core is assembled and fastened through the through coupling of the fastening portion for the perforations, the upper and lower covers are disposed on the amorphous laminate. At this time, the inductor core is preferably subjected to an anti-oxidation coating process around the outer wall in a short time by spraying or dipping.
Subsequently, magnetic field heat treatment is performed on the inductor core in order to relieve the magnetic properties of the amorphous laminate and the stress in the laminate assembly (S903). At this time, the heat treatment step is carried out for 2 to 10 hours at a temperature condition of 380 ℃ ~ 450 ℃. This heat treatment process may be carried out before or after the oxidation coating process.
Then, after the magnetic circuit is formed by the combination of the at least two inductor core, the bobbin is coupled to the legs of the inductor core and the coil is wound to manufacture the inductor (S904). In this case it is also possible to couple the coiled bobbin to the legs of the inductor core. At this time, the inductor has a magnetic circuit formed of any one of a multi-gap type structure, a normal gap type structure, a one-way gap type structure, and an L type structure. Here, when at least two inductor cores are combined, it is preferable to be fixed to the outer circumference of the combined inductor core by a fixing band made of sus or silicon steel strip.
Meanwhile, an inductor may be manufactured by winding a coil after the inductor core is embedded in a flanged case. In this case, the inductor is preferably formed of a magnetic circuit having a normal gap type structure.
Here, only the case where the inductor core is manufactured by using the I-type and C-type single thin plates is described, but the inductor core may be manufactured by stacking a plurality of E-type, T-type, and trapezoidal single thin plates as necessary. In this case, the E-type and T-type inductor cores may be formed of a single-type structure punched out of the E-type and T-type, or may be formed of a combination structure of I-type single thin plates. The trapezoidal inductor core is formed by stacking the left and right oblique directions of the I-type single thin plate. The trapezoidal inductor core is arranged on four sides of the square to form a square inductor. Detailed description thereof will be omitted since it can be easily understood by those skilled in the art through the foregoing.
FIG. 10 is a graph illustrating a comparison of the inductor core of FIG. 3A and FIG. 3B with a conventional inductor core. FIG. Here, the conventional inductor core is manufactured by cutting the core to a C-type inductor core after winding the core.
In this case, the
In addition, each
As shown in FIG. 10, the
While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be construed as limited to the embodiments set forth herein. Various changes and modifications may be made by those skilled in the art.
11: Type I laminate 12: Top cover
13:
14b: support 100: inductor core
Claims (21)
Upper and lower covers for covering upper and lower portions of the amorphous laminate; And
A fastening part for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate,
The fastening portion
A support having one end fixed to the upper cover or the lower cover and extending through the perforation of the amorphous laminate; And
An inductor core coupled to the other end of the support, the fastening member configured to integrate the upper cover, the amorphous stack, and the lower cover.
A bobbin mounted to and insulated a leg of the inductor core; And
At least one coil wound on the bobbin,
Each of the inductor cores,
An amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one perforation formed thereon are laminated;
Upper and lower covers for covering upper and lower portions of the amorphous laminate; And
And a fastening portion for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.
A case including the inductor core therein and having a flange for separating a portion corresponding to a leg of the inductor core at an outer circumference thereof; And
A coil wound along the flange of the case,
The inductor core,
An amorphous laminate in which a plurality of single thin plates of amorphous metal having at least one perforation formed thereon are laminated;
Upper and lower covers for covering upper and lower portions of the amorphous laminate; And
And a fastening portion for integrally aligning and assembling the upper and lower covers through the perforation of the amorphous laminate.
A first step of creating a single sheet having a perforation formed from a ribbon of amorphous metal;
A second step of forming an inductor core by integrating the amorphous laminate, the upper and lower covers by disposing an upper and lower cover on the amorphous laminate on which the single thin plate is laminated, and then engaging fastening portions for perforations;
Performing a heat treatment on the inductor core; And
A fourth step of manufacturing an inductor having a magnetic circuit by combining the heat-treated inductor cores into at least two;
Method of manufacturing an inductor comprising a.
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
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KR102131584B1 (en) * | 2019-04-02 | 2020-07-09 | 한국전력공사 | Structure or Method of Transformer Core for Saturation Flux Reduction |
KR102136026B1 (en) * | 2019-04-03 | 2020-07-20 | 한국전력공사 | Combined structure of variable-capacity transformer structure using ferrite core for magnetic flux assistance and method for manufacturing the same |
KR102139004B1 (en) * | 2019-04-02 | 2020-07-28 | 한국전력공사 | Variable-capacity transformer structure using magnetic flux assist slot and manufacturing method thereof |
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2010
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR102131584B1 (en) * | 2019-04-02 | 2020-07-09 | 한국전력공사 | Structure or Method of Transformer Core for Saturation Flux Reduction |
KR102139004B1 (en) * | 2019-04-02 | 2020-07-28 | 한국전력공사 | Variable-capacity transformer structure using magnetic flux assist slot and manufacturing method thereof |
KR102136026B1 (en) * | 2019-04-03 | 2020-07-20 | 한국전력공사 | Combined structure of variable-capacity transformer structure using ferrite core for magnetic flux assistance and method for manufacturing the same |
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